Systems and Methods for a Roll-Up Door
A roll-up door assembly includes a header, a face frame, and a lift frame. The lift frame is removably coupled to the header and is configured to be conveniently discarded once the header is securely installed to the face frame. The header further includes links along at least one end of individual slats that comprise a door panel. The links and the slats are configured to be rolled and unrolled from a spiral as the door panel is opened and closed. The links include a noise abatement feature that is adapted to decrease a sound pressure level associated with the links impacting, for instance, one another during the process opening and closing the door. The links further include a friction reduction surface that reduces friction at the coupling of adjacent links.
This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62/989,073 filed on Mar. 13, 2020, the disclosure of which is hereby incorporated by reference for all purposes.
STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENTNot applicable.
TECHNICAL FIELDThe present disclosure is generally related to a roll-up door with slats that are rolled up into a coil of several layers or paid out to provide the slats generally in a plane as a closure over an opening.
BACKGROUNDRoll-up doors can include a door panel that comprises a series of adjacent slats. The slats are rolled onto a reel assembly to create a drum or barrel assembly, which is housed within a header of the roll-up door. In such roll-up doors, individual links are connected to the lateral ends of the slats (e.g., via endcaps), and the links along each side edge of the door panel are hingedly coupled to one another. The links are coiled to stack on top of one another when the door panel is rolled up and can be configured to prevent the slats from contacting each other. In general, the roll-up door is configured such that the door panel, at the point at which it departs from the reel near the header, maintains a substantially coplanar entry and exit orientation with side guides along the door face frame (e.g., legs/jambs) as the door closes and opens. The controlled entry and exit dynamics generally reduce friction, increase speed, diminish noise, and facilitate self-alignment of each slat of the door panel.
During a typical installation process of a roll-up door assembly, the roll-up door generally requires use of a lift truck to assist with the installation of the header above the doorway or opening that will be selectively covered by the door panel. As such, a frame is often secured to the header when shipped from a manufacturer. The frame provides a support structure for the lift truck to engage without damaging the roll-up door panel assembly. Oftentimes the frame is removed from the header following the securement of the roll-up door assembly to the wall. As a result, the frame must be removed and disposed of at the jobsite, which can be costly and burdensome, especially when the frame is of a metallic construction.
In addition to certain challenges faced during installation of a roll-up door assembly, other issues arise during operation of the roll-up door. For example, while the controlled entry and exit of the door panel generally reduces noise from excessive contact between the door panel and certain structures of the door assembly, such as the side guides, there remains a relatively high sound pressure level caused by the links secured to the individual door slats. In particular, while the door panel is opening at high speeds, the links, which are often constructed from plastic, are being quickly coiled into contact with adjacent links, resulting in an undesirably high sound pressure level. Furthermore, the cyclical high-speed winding and unwinding of the plastic links from the barrel assembly imparts an angular loading on the hinged coupling between links. As a result, fatigue and wear between links can be exacerbated at the coupling (e.g., pin bores) and require additional maintenance to inhibit premature repair and/or replacement of the links.
Therefore, in view of at least the above, a need exists for a roll-up door assembly having improved link sound abatement and link wear management, as well as enhanced support frame implementation for the installation and use of the roll-up door assembly.
SUMMARYSome embodiments described herein provide a door assembly that includes a header, a face frame, and a lift frame. The header can be configured as a roll-up door with a door panel including slats on a reel. The face frame can be configured as side guides that can be positioned adjacent to the sides of a doorway and configured to guide the door panel when the door panel is moved between an opened and a closed position. The lift frame is removably coupled to the header and is configured as a support structure that a lift truck, or the like, may interface with during installation of the header. The lift frame can be decoupled from the header and discarded after the header is secured to the face frame.
In some embodiments, the lift frame is a renewable and/or a recyclable material. In some embodiments, the lift frame incorporates one or more wooden supports. The wooden supports can comprises one or more wood truss sections, such as pre-engineered first and second I-beams. The wooden truss may further include a plurality of crossbeams that engage each of the first and second I-beams. The crossbeams may be wooden and configured to be removably coupled with the header at a plurality of locations along the header. Furthermore, the wooden truss may include wooden support beam assemblies configured to be engaged by a lift truck.
Some embodiments described herein provide a roll-up door assembly with a door panel including slats engaged with a reel that can be rotated in one direction so as to roll up the slats into a coil of several layers on the reel, or rotated in an opposite direction so as to pay out the slats from the coil generally in a closure plane adjacent a doorway. The slats includes links coupled to each end of the slat, such as via endcaps. The links along respective edges of the slats are hingedly coupled to one another, and are configured to stack on top of one another (e.g., nest) when the door panel is rolled up, thus inhibiting adjacent slats from contacting each other.
In other embodiments, the links have cooperating structures on inner sides and outer surfaces so that the links guide and nest with each other when stacked up on top of one another (e.g., coiled) in a retracted or opened state of the door. The links may include both a rigid material and a relatively softer material. The softer material can be applied to a link contact zone such that when a first link engages a second link, the sound pressure produced by the impact engagement is at least partially absorbed and reduced.
In some embodiments, the links include a rib and a groove. The rib is dimensioned to nest within the groove of adjacent links as the links are rolled or coiled into a spiral formation, such as when the door panel of the roll-up door is opening or is in an opened position. In some embodiments, the groove includes a secondary channel disposed within the groove. The secondary channel is configured to receive a flexible insert comprising a relatively softer, resilient material. In some embodiments, the flexible insert is configured as a urethane strip. The urethane strip is configured to provide sound abatement when a rib from a first link nests with a groove of a second link within which at least a portion of the urethane strip is positioned. In other embodiments, the flexible insert may include additional or alternative polymers, such as rubber, for example.
In some embodiments, a link for use in a roll-up door includes a retention bore and a threaded bore on a first end of the link, and a pivot bore on a second end of the link. The threaded bore includes threads on an inner surface that are configured to engage a threaded pin (e.g., a shoulder bolt). The threaded pin bolt can extend through each of the retention bore and the threaded bore of one link and through a pivot bore of another link, such that the pivot bore is positioned between the retention bore and the threaded bore, thereby coupling the links together. In one embodiment, the pivot bore may include a plastic compatible lubricant configured to lower friction between an inner surface of the pivot bore and the threaded pin.
In further embodiments, the pivot bore may include a bearing disposed adjacent an inner surface of the pivot bore. In some embodiments, the bearing may be a sleeve bearing configured to engage the inner surface of the pivot bore and dimensioned to slideably receive the threaded pin. In some embodiments, the sleeve bearing is configured to reduce friction and can be impregnated with a compatible lubricant. In some embodiments, the sleeve bearing is configured to be more wear resistant as compared to the pivot bore.
The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict select embodiments and are not intended to limit the scope of embodiments of the invention. Given the benefit of this disclosure, skilled artisans will recognize the examples provided herein have many useful alternatives that fall within the scope of the invention.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” and variations thereof, herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled,” and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. Likewise, the phrases “at least one of A, B, and C,” “one or more of A, B, and C,” and the like, are meant to indicate A, or B, or C, or any combination of A, B, and/or C.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Given the benefit of this disclosure, various modifications to the illustrated embodiments will be readily apparent to those skilled in the art and the underlying principles herein can be applied to other embodiments and applications without departing from the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.
As discussed above, a roll-up door assembly may include a header that houses various components including slats that make up the door panel. Prior to installation, the header may be coupled to a lift frame that is configured to provide a support structure, such that a lift truck may engage the roll-up door assembly at the lift frame without damaging the door panel or other components of the header. Following the installation of the header above a doorway, the lift frame is removed from the header and requires disposal from the jobsite, which is often costly and inconvenient. Furthermore, in use, conventional roll-up doors assemblies emit a relatively high sound pressure level when moved between a closed position and an opened position. In particular, plastic links that engage individual slats of the door panel coil onto one another and the impact of that coiling produces at least some of the undesirable noise. Additionally, when links are configured to form a lifting chain (e.g., when pivotally connected in an end-to-end fashion) the links are often subject to high loads and cyclical fatigue forces.
In some embodiments, a roll-up door assembly according to the invention can address many undesirable issues of traditional roll-up doors. For example, in some embodiments, the roll-up door assembly includes a removable lift frame that reduces the burdens related to the manufacture, disposal, and expense associated with traditional installation protocol. In particular, the removable lift frame may be primarily constructed of wood that is renewable and easily disposable and/or recyclable. Furthermore, in some embodiments, a roll-up door assembly includes a plurality of links disposed at the ends of each slat of a door panel; the links can include a flexible/resilient insert that can reduce or abate the noise associated with the coiling and nesting links during operation of the roll-up door. In some embodiments, the links can additionally or alternatively be configured to reduce friction between subsequent links, such as with selective application of a lubricant, a bearing, and/or some combination thereof.
The roll-up door assembly of the present disclosure includes a link assembly at each end of the header. In other forms, particular application requirements may result in use of a link assembly at only one end of the header. It is further understood that each link assembly includes a plurality of links, and throughout the disclosure, the links may be described in terms of a single link or multiple links. The description of a single link, unless otherwise specified, can be applied to all the links of the plurality of links in the link assembly. Additionally, some illustrations and descriptions of engagements of multiple links may use identical reference numbers though referring to separate links of the link assembly.
Referring now to
In the illustrated embodiment, the plurality of crossbeams 132 is configured as four crossbeams 132 that are distributed across and secured to an upper flange of each of the first I-beam 124 and the second I-beam 128. The crossbeams 132 can be fastened (e.g., screwed) to the upper flange of the I-beams 124, 128. The crossbeams 132 provide anchor and/or support points between the header 104 and the lift frame 120. In one example, each of the end crossbeams 132 is adjacent to a metallic angle iron 133 that is also secured to the upper flange of each of the I-beams 124, 128. The angle irons 133 each define a vertical flange 134 that is configured to engage and selectively couple to the header 104. In other forms, straps, bands, and the like can be incorporated to temporarily secure the header 104 to the lift frame 120. Additionally, the plurality of support beam assemblies 136 are configured as four support beam assemblies 136 spaced across and secured to a lower flange of each of the first I-beam 124 and the second I-beam 128, opposite to the upper flange. As shown in
In general, the lift frame 120 provides a support structure for a lift truck or other installation aid to engage without undesirably contacting and/or damaging the slats 112 of the door panel 108, or other components of the header 104. While an example of a truss structure is illustrated in
Referring now to
Turning to
With additional reference to
The reel assembly 116 further includes a guide system that maintains a tangent between the reel assembly 116 and a closure plane of the doorway at the point of entry and exit of the door panel 108 to and from the header 104. In particular, the guide system maintains an aligned entry and exit of the links 156 within the side rails 152 of the face frame 148. Additional details and example embodiments of the reel assembly 116 and other components of the roll-up door assembly 100, such as the engagement of the links 156 and the slats 112, for example, are described in U.S. Pat. No. 10,344,527 entitled “Roll-Up Door” that issued on Jul. 9, 2019, which is hereby incorporated by reference.
Referring now to
As shown in
Each link 156 further includes a first end 176 and a second end 180. Each of the first end 176 and the second end 180 include a first hinge structure 184 and a second hinge structure 188, respectively. In general, the first hinge structure 184 of one link 156 can be pivotally connected with a second hinge structure 188 of another, adjacent link 156 in the link assembly 158 in an end-to-end fashion. Referring again to
As illustrated, the first hinge structure 184 includes a retention bore 192 and a threaded bore 196 (e.g., such as provided via a threaded insert). Additionally, the second hinge structure 188 includes a pivot bore 200. Each of the retention bore 192, the threaded bore 196, and the pivot bore 200 are dimensioned to receive a hinge member, such as a threaded pin in the form of a shoulder bolt 204 (see, for example,
Referring now to
Each of
In the illustrated embodiment, the secondary channel 224 further includes slanted projections 236 (see, for example,
Referring now to
As introduced above, in some embodiments, the sleeve bearing 220 can be inserted between the pivot bore 200 and the smooth cylindrical portion 252 of the shoulder bolt 204. The bearing 220 can be implemented to decrease friction at and overall wear of the second hinge structure 188. In additional or in alternative embodiments, lubrication may be used in combination with the sleeve bearing 220. In some embodiments, the lubrication may be applied to one or both of the shoulder bolt 204 and the pivot bore 200 before the links 156 are assembled. In other embodiments, lubrication may be applied to the pivot bore 200 after the shoulder bolt 204 is received therein and as-needed throughout the life of the roll-up door assembly 100. Further still, the bearing 220 can take on a variety of form factors (e.g., split ring, flange, etc.) and can be impregnated with a lubricant. The lubrication, whether used in a bearing arrangement or not, is selected to accommodate application specific material (e.g., plastic compatible) and duty cycle requirements. In some forms, the lubrication can include non-migrating, high pressure lubrication that is compatible with the application-specific plastic, such as TEFLON impregnated silicone lubricating grease.
As further illustrated in
The flexible insert 240, as illustrated, generally has a circular cross section, but can be slightly deformed from a natural form factor when received within the secondary channel 224. In particular, the flexible insert may be deformed when pressed through the opening 232 of the secondary channel 224, which, as described above, is generally narrower than the base 228 of the secondary channel 224. The contours of the secondary channel 224, such as the narrower opening 232, can be configured to restrain the insert 240 and inhibit undesired removal of the insert 240 during operation. In other example embodiments, an adhesive may be used to secure the insert 240 in a desired location/position, such as by use of adhesive at a single discrete, limited segment/point along the insert 240, and not the entire length of the insert 240. In some embodiments, the flexible insert 240 is generally unbiased and not pre-formed prior to being inserted into the secondary channel 224. As such, the flexible insert 240 can take at least a portion of the shape and contour of the secondary channel 224, as illustrated by the slight curvature and contouring of the flexible insert 240 shown in
Referring now to
Further illustrated in
One example of ribs 168 engaging grooves 172 is shown in
As shown in
The example embodiment of the sound abatement concept is further described with additional reference to
Given the benefit of this disclosure, one of ordinary skill in the art will appreciate that alternative arrangements are available to provide a noise/sound abatement configuration (e.g., insert 240 and secondary channel 224) at the interfaces between multiple links. For instance, alternatively or additionally, the form factors (e.g., sizes, shapes, dimensions, relative positions, and the like) of the cooperating insert and channel structures may be altered while maintaining the desired abatement. In still other embodiments, the examples can include incorporation of an insert seated in a groove/secondary channel formed on the rib along the outer rib interface surface of the links, thus effectively swapping the functions of the rib and the groove/secondary channel.
Any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with different embodiments. As noted previously, it will be appreciated by those skilled in the art that while the disclosure has been described above in connection with particular embodiments and examples, the disclosure is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments, examples, and uses are intended to be encompassed by the accompanying claims. For example, the noise abatement features and concepts can be employed with other types of roll-up doors that include for form of link engagement. Various features and advantages of the invention are set forth in the following claims.
Claims
1. A roll-up door assembly comprising:
- a plurality of links operatively coupled and configured to coil and uncoil during use, at least some of the plurality of links include at least one of a rib and a groove, wherein the ribs and the grooves are configured such that the rib can nest within the groove when the plurality of links are coiled;
- a secondary channel in at least one of the groove and the rib of a first link of the at least some of the plurality of links; and
- an insert seated within the secondary channel and configured to extend beyond the secondary channel to interface with the groove or the rib of a second link of the at least some of the plurality of links coiled to stack with the first link.
2. The roll-up door assembly of claim 1, wherein the secondary channel is formed in the groove of the first link.
3. The roll-up door assembly of claim 2, wherein:
- the secondary channel defines a length along the first link; and
- the insert is sized to extend the length of the secondary channel.
4. The roll-up door assembly of claim 2, wherein the secondary channel and the insert are configured such that the insert can be fully deformed into a cavity defined by the secondary channel when the insert is urged into the cavity by the rib of the second link.
5. The roll-up door assembly of claim 4, wherein the secondary channel and the insert are configured such that a rib interface surface of the rib of the second link directly engages with a groove interface surface when the insert is fully deformed into the cavity defined by the secondary channel.
6. The roll-up door assembly of claim 2, wherein the secondary channel and the insert are configured such that the rib of the second link initially engages the insert when the rib of the second link is nested with the groove of the first link.
7. The roll-up door assembly of claim 1, wherein the secondary channel defines opposing sidewalls that are oriented tangential to an outer surface of the insert.
8. The roll-up door assembly of claim 1, wherein:
- the secondary channel comprises a plurality of secondary channels formed in the grooves of multiple successive links of the plurality of links; and
- the insert comprises a continuous insert seated within the plurality of secondary channels of the multiple successive links.
9. The roll-up door assembly of claim 1, wherein the insert comprises multiple segmented inserts seated within the secondary channel.
10. The roll-up door assembly of claim 1, wherein the insert comprises at least one of a strip and a coating.
11. The roll-up door assembly of claim 1, wherein the insert defines a circular cross section transverse to a longitudinal axis of the insert.
12. The roll-up door assembly of claim 1, wherein the ribs and the grooves of the at least some of the plurality of links are arcuate.
13. A link capable of use with a roll-up door, the link comprising:
- a rib;
- a groove opposite to the rib;
- a secondary channel in one of the rib and the groove; and
- an insert seated in and extending from the secondary channel.
14. The link of claim 13, wherein the secondary channel is formed in the groove.
15. The link of claim 14, wherein:
- the secondary channel defines a cavity;
- the insert defines a volume; and
- the cavity is sized to accommodate the volume of the insert.
16. The link of claim 13, wherein the secondary channel includes a projection configured to inhibit linear migration of the insert along the secondary channel.
17. The link of claim 13, wherein:
- the link is arcuate; and
- the groove defines a form factor that is the inverse of the rib.
18. The link of claim 13, the link further comprising:
- a first hinge structure proximate a first end of the link; and
- a second hinge structure proximate a second end of the link;
- wherein the secondary channel extends from the first end to the second end and at least partially about the second hinge structure whereat the secondary channel terminates in a tapered end.
19. The link of claim 13, wherein:
- the groove defines an interior surface;
- the secondary channel is formed in the interior surface of the groove and defines a base with opposing sidewalls that extend from the base;
- the opposing sidewalls are oriented tangential to an outer surface of the insert when the insert is its natural form within the secondary channel; and
- the secondary channel and the insert are configured such that at least a portion of the insert extends beyond the interior surface of the groove when the insert is seated within the secondary channel.
20. A roll-up door assembly, comprising:
- a plurality of links coupled end-to-end and configured to spiral during use;
- a first link of the plurality of links defines a rib;
- a second link of the plurality of links defines a groove sized to receive the rib;
- a secondary channel formed in at least one of the rib and the groove; and
- an insert seated in the secondary channel and extending at least partially out of the secondary channel.
Type: Application
Filed: Mar 12, 2021
Publication Date: Sep 16, 2021
Inventor: Scott E. Booker (Oconomowoc, WI)
Application Number: 17/200,542